Manufacturer Invests $170k in Safety After Serious Machine Injury

Alpine MDF Industries Pty Ltd has committed $170,800 to safety improvements after entering into an enforceable undertaking in the Wangaratta Magistrates' Court, where it faced three charges of failing to provide or maintain a safe workplace.

The undertaking was accepted on Monday 2 February. WorkSafe Victoria retains the right to reinstate the charges if Alpine MDF breaches or withdraws from the agreement, underscoring the ongoing obligation on duty holders to maintain effective work health and safety controls, including documented policies and WHS management systems.

The case relates to a June 2023 incident in which two workers were directed to clean a machine used to paint ready-made medium density fibreboard (MDF). The plant included two applicator rollers arranged to create a significant danger zone when in operation.

This danger area was guarded by a hinged cover fitted with an interlock designed to stop the rollers when the guard was opened. Management had been advised that the interlock system was not functioning. As a temporary control, a safety lanyard and padlock were fitted to the closed guard to prevent access until a replacement interlock could be installed. Under this interim arrangement, cleaning was only to be carried out under the supervision of an electrician, with the power isolated from the plant.

On the day of the incident, the two workers were given the key to the padlock and instructed to clean the machine without supervision. The plant had not been isolated from its power source, and the rollers remained capable of operating.

During the cleaning process, one worker’s rag became entangled in the rotating rollers, pulling his arm into the machine up to his elbow. The injury caused extensive tissue damage above the elbow, requiring skin grafts and resulting in a serious, long-term harm.

WorkSafe alleges it was reasonably practicable for Alpine MDF to establish and maintain a safe system of work for cleaning the machine while the interlock was inoperative. This should have included mandatory isolation of power before accessing the rollers and clear procedures detailing the interim controls.

It is further alleged that Alpine MDF failed to provide adequate supervision, information, instruction and training to workers regarding the temporary guarding arrangement and the associated safe work method. In similar situations, employers are expected to implement and communicate formal Safe Work Method Statements (SWMS) and plant-specific procedures to ensure high-risk tasks are carried out safely. Resources for developing such documents are readily available from specialist providers such as Bluesafe SWMS templates.

The enforceable undertaking, with an estimated value of $170,800, requires Alpine MDF to invest in safety initiatives aimed at improving machine guarding, isolation procedures, worker training and broader industry safety awareness. These measures are intended to strengthen the company’s WHS management system and reduce the likelihood of similar incidents, both within the business and across the timber sector.

WorkSafe Chief Health and Safety Officer, Sam Jenkin, reminded all duty holders that they have a clear obligation to ensure plant and associated systems of work are safe before use.

Mr Jenkin cautioned that when faulty machinery, including equipment operating without effective safeguards, is used, the risk of a serious or life-changing incident is effectively inevitable over time. He emphasised that incidents like this are preventable where robust isolation procedures, guarding, SWMS, training and supervision are in place and actively monitored.

He also noted it was encouraging to see Alpine MDF committing to plant upgrades and additional safety resources designed to lift standards at its own workplace and contribute to improved safety outcomes across the wider timber industry.

The incident serves as a reminder to all businesses using plant and equipment to regularly review their WHS management systems, ensure interlocks and guards are functional, verify that interim controls are clearly documented, and confirm that workers are properly trained and supervised whenever they are required to clean, maintain or access hazardous machinery.